Quasi-resonant flyback converter for an induction-based aerosol delivery device

ABSTRACT

An aerosol delivery device is provided that includes an aerosol precursor composition and a quasi-resonant flyback converter configured to cause components of the aerosol precursor composition to vaporize to produce an aerosol. The quasi-resonant flyback converter includes a transformer including an induction transmitter and an induction receiver, a capacitor that with the induction transmitter forms a tank circuit. The quasi-resonant flyback converter also includes a transistor that is switchable in cycles to cause the induction transmitter to generate an oscillating magnetic field and induce an alternating voltage in the induction receiver when exposed to the oscillating magnetic field, the alternating voltage causing the induction receiver to generate heat and thereby vaporize components of the aerosol precursor composition.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.15/836,086, filed Dec. 8, 2017, the contents of which are hereinincorporated by reference in their entirety.

TECHNOLOGICAL FIELD

The present disclosure relates to aerosol delivery devices such aselectronic cigarettes and heat-not-burn cigarettes, and moreparticularly to an induction-based aerosol delivery device. The aerosoldelivery device may be configured to heat an aerosol precursorcomposition, which may be made or derived from tobacco or otherwiseincorporate tobacco, to form an inhalable substance for humanconsumption.

BACKGROUND

Many smoking articles have been proposed through the years asimprovements upon, or alternatives to, smoking products based uponcombusting tobacco. Exemplary alternatives have included devices whereina solid or liquid fuel is combusted to transfer heat to tobacco orwherein a chemical reaction is used to provide such heat source.Examples include the smoking articles described in U.S. Pat. No.9,078,473 to Worm et al., which is incorporated herein by reference.

The point of the improvements or alternatives to smoking articlestypically has been to provide the sensations associated with cigarette,cigar, or pipe smoking, without delivering considerable quantities ofincomplete combustion and pyrolysis products. To this end, there havebeen proposed numerous smoking products, flavor generators, andmedicinal inhalers which utilize electrical energy to vaporize or heat avolatile material, or attempt to provide the sensations of cigarette,cigar, or pipe smoking without burning tobacco to a significant degree.See, for example, the various alternative smoking articles, aerosoldelivery devices and heat generating sources set forth in the backgroundart described in U.S. Pat. No. 7,726,320 to Robinson et al.; and U.S.Pat. App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; and2014/0096781 to Sears et al., which are incorporated herein byreference. See also, for example, the various types of smoking articles,aerosol delivery devices and electrically powered heat generatingsources referenced by brand name and commercial source in U.S. Pat. App.Pub. No. 2015/0220232 to Bless et al., which is incorporated herein byreference. Additional types of smoking articles, aerosol deliverydevices and electrically powered heat generating sources referenced bybrand name and commercial source are listed in U.S. Pat. App. Pub. No.2015/0245659 to DePiano et al., which is also incorporated herein byreference. Other representative cigarettes or smoking articles that havebeen described and, in some instances, been made commercially availableinclude those described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S.Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No. 5,249,586 to Morganet al.; U.S. Pat. No. 5,388,594 to Counts et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,726,320 to Robinson et al.; U.S. Pat. No. 7,896,006 toHamano; U.S. Pat. No. 6,772,756 to Shayan; US Pat. Pub. No. 2009/0095311to Hon; US Pat. Pub. Nos. 2006/0196518, 2009/0126745, and 2009/0188490to Hon; US Pat. Pub. No. 2009/0272379 to Thorens et al.; US Pat. Pub.Nos. 2009/0260641 and 2009/0260642 to Monsees et al.; US Pat. Pub. Nos.2008/0149118 and 2010/0024834 to Oglesby et al.; US Pat. Pub. No.2010/0307518 to Wang; and WO 2010/091593 to Hon, which are incorporatedherein by reference.

Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOVE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byLorillard Technologies, Inc.; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by EPUFFER® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® byGreen Smoke Inc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™, HENDU™JET™, MAXXQ™, PINK™ and PITBULL™ by SMOKE STIK®; HEATBAR™ by PhilipMorris International, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7™;LOGIC™ and THE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.;METRO® by Nicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SSChoice LLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPPE-MYSTICK™ by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products,LLC; RUYAN® by Ruyan Group (Holdings) Ltd.; SF® by Smoker FriendlyInternational, LLC; GREEN SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MisticMenthol product by Mistic Ecigs; and the Vype product by CN CreativeLtd. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; SOUTH BEACHSMOKE™.

Articles that produce the taste and sensation of smoking by electricallyheating tobacco or tobacco derived materials have suffered frominconsistent performance characteristics. Electrically heated smokingdevices have further been limited in many instances by requiring largebattery capabilities. Accordingly, it is desirable to provide a smokingarticle that can provide the sensations of cigarette, cigar, or pipesmoking, without substantial combustion, and that does so throughinduction heating.

BRIEF SUMMARY

The present disclosure relates to aerosol delivery devices configured toproduce aerosol and which aerosol delivery devices, in someimplementations, may be referred to as electronic cigarettes orheat-not-burn cigarettes. As described hereinafter, the aerosol deliverydevices include a quasi-resonant flyback converter with a transformerincluding an induction transmitter and an induction receiver. Theinduction transmitter may include a coil configured to create anoscillating magnetic field (e.g., a magnetic field that variesperiodically with time) when alternating current is directedtherethrough. The induction receiver may be at least partially receivedwithin the induction transmitter and may include a conductive material.Thereby, by directing alternating current through the inductiontransmitter, eddy currents may be generated in the induction receivervia induction. The eddy currents flowing through the resistance of thematerial defining the induction receiver may heat it by Joule heating.Thereby, the induction receiver, which may define an atomizer, may bewirelessly heated to form an aerosol from an aerosol precursorcomposition positioned in proximity to the induction receiver. Wirelessheating, as used herein, refers to heating that occurs via an atomizerthat is not physically electrically connected to the (electrical) powersource.

The present disclosure includes, without limitation, the followingexample implementations.

Some example implementations provide an aerosol delivery devicecomprising an aerosol precursor composition and a quasi-resonant flybackconverter configured to cause components of the aerosol precursorcomposition to vaporize to produce an aerosol, the quasi-resonantflyback converter comprising a transformer including an inductiontransmitter and an induction receiver; a capacitor that with theinduction transmitter forms a tank circuit; and a transistor that isswitchable in cycles to cause the induction transmitter to generate anoscillating magnetic field and induce an alternating voltage in theinduction receiver when exposed to the oscillating magnetic field, thealternating voltage causing the induction receiver to generate heat andthereby vaporize components of the aerosol precursor composition,wherein each of the cycles includes an on-interval in which thetransistor is switched on to enable current through the inductiontransmitter that causes the induction transmitter to generate a magneticfield in which the induction transmitter stores energy, and anoff-interval in which the transistor is switched off to disable currentthrough the induction transmitter that causes a collapse of the magneticfield, and the collapse of the magnetic field causes a transfer of theenergy from the induction transmitter to the induction receiver, andcharges the capacitor and thereby causes a voltage waveform at a drainof the transistor, and wherein the quasi-resonant flyback converterfurther comprises a comparator with two input terminals coupled toeither side of the capacitor between the capacitor and the drain of thetransistor, the comparator being configured to detect a trough in thevoltage waveform during the off-interval in which the transistor isswitched off, and in response produce an output to cause the transistorto switch on for the on-interval.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the aerosol precursor composition includes asolid tobacco material, a semi-solid tobacco material or a liquidaerosol precursor composition.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the quasi-resonant flyback converter furthercomprises first and second voltage dividers whose inputs are coupled toeither side of the capacitor, the two input terminals of the comparatorbeing coupled to outputs of respective ones of the first and secondvoltage dividers and thereby coupled to either side of the capacitor.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the comparator is implemented by a coprocessorthat is also configured to implement a pulse-width modulation (PWM)controller that is configured to receive the output from the comparator,and in response drive the transistor to switch on for the on-interval.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the coprocessor is further configured toimplement a glitch filter coupled to and between the comparator and PWMcontroller, the glitch filter being configured to receive and removeglitch pulses from the output of the comparator and thereby produce afiltered output, and the PWM controller is configured to receive thefiltered output, and in response drive the transistor to switch on forthe on-interval.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the coprocessor is embodied as a programmablesystem-on-chip (PSoC).

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the comparator is implemented by a coprocessorthat is also configured to implement a glitch filter that is configuredto receive and remove glitch pulses from the output of the comparator.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the coprocessor is embodied as a programmablesystem-on-chip (PSoC).

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the comparator is implemented by a coprocessorthat is embodied as a programmable system-on-chip (PSoC), and that isalso configured to implement a pulse-width modulation (PWM) controllerand a glitch filter coupled to and between the comparator and PWMcontroller, and wherein the glitch filter is configured to receive andremove glitch pulses from the output of the comparator and therebyproduce a filtered output, and the PWM controller is configured toreceive the filtered output, and in response drive the transistor toswitch on for the on-interval.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the comparator is implemented by an individualelectronic component or a circuit constructed of discrete electroniccomponents.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the transistor has a drain-to-source on-stateresistance (R_(DS(on))) that is inversely proportional to a switchingtime of the transistor, and that is directly proportional to a time inwhich the alternating voltage is induced in the induction receiver andthereby the heat is generated.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the aerosol delivery device further comprises apower source connected to an electrical load that includes thetransformer, the power source being configured to supply a current tothe load, an amount of the heat the induction receiver is caused togenerate being directly proportional to an intensity of the currentsupplied by the power source.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the power source includes a rechargeableprimary battery and a rechargeable secondary battery in a parallelcombination.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the induction receiver includes a coil, anamount of the heat the induction receiver is caused to generate beingdirectly proportional to a length of the coil.

Some example implementations provide a control body for an aerosoldelivery device, the control body comprising a housing having an openingdefined in one end thereof, the opening configured to receive an aerosolsource member that defines a heated end and a mouth end and includes anaerosol precursor composition; and within the housing, a quasi-resonantflyback converter comprising: a transformer including an inductiontransmitter and an induction receiver; a capacitor that with theinduction transmitter forms a tank circuit; and a transistor that isswitchable in cycles to cause the induction transmitter to generate anoscillating magnetic field and induce an alternating voltage in theinduction receiver when exposed to the oscillating magnetic field, thealternating voltage causing the induction receiver to generate heat and,when the aerosol source member is inserted into the housing, vaporizecomponents of the aerosol precursor composition to produce an aerosol,wherein each of the cycles includes an on-interval in which thetransistor is switched on to enable current through the inductiontransmitter that causes the induction transmitter to generate a magneticfield in which the induction transmitter stores energy, and anoff-interval in which the transistor is switched off to disable currentthrough the induction transmitter that causes a collapse of the magneticfield, and the collapse of the magnetic field causes a transfer of theenergy from the induction transmitter to the induction receiver, andcharges the capacitor and thereby causes a voltage waveform at a drainof the transistor, and wherein the quasi-resonant flyback converterfurther comprises a comparator with two input terminals coupled toeither side of the capacitor between the capacitor and the drain of thetransistor, the comparator being configured to detect a trough in thevoltage waveform during the off-interval in which the transistor isswitched off, and in response produce an output to cause the transistorto switch on for the on-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the quasi-resonant flyback converter further comprisesfirst and second voltage dividers whose inputs are coupled to eitherside of the capacitor, the two input terminals of the comparator beingcoupled to outputs of respective ones of the first and second voltagedividers and thereby coupled to either side of the capacitor.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isalso configured to implement a pulse-width modulation (PWM) controllerthat is configured to receive the output from the comparator, and inresponse drive the transistor to switch on for the on-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isalso configured to implement a glitch filter that is configured toreceive and remove glitch pulses from the output of the comparator.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isembodied as a programmable system-on-chip (PSoC), and that is alsoconfigured to implement a pulse-width modulation (PWM) controller and aglitch filter coupled to and between the comparator and PWM controller,and wherein the glitch filter is configured to receive and remove glitchpulses from the output of the comparator and thereby produce a filteredoutput, and the PWM controller is configured to receive the filteredoutput, and in response drive the transistor to switch on for theon-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by an individualelectronic component or a circuit constructed of discrete electroniccomponents.

Some example implementations provide a control body for an aerosoldelivery device, the control body comprising a housing coupled orcoupleable with a cartridge that is equipped with an induction receiverand contains an aerosol precursor composition; and within the housing, aquasi-resonant flyback converter comprising: an induction transmitterthat with the induction receiver forms a transformer; a capacitor thatwith the induction transmitter forms a tank circuit; and a transistorthat is switchable in cycles to cause the induction transmitter togenerate an oscillating magnetic field and induce an alternating voltagein the induction receiver when the housing is coupled with the cartridgeand the induction receiver is exposed to the oscillating magnetic field,the alternating voltage causing the induction receiver to generate heatand thereby vaporize components of the aerosol precursor composition toproduce an aerosol, wherein each of the cycles includes an on-intervalin which the transistor is switched on to enable current through theinduction transmitter that causes the induction transmitter to generatea magnetic field in which the induction transmitter stores energy, andan off-interval in which the transistor is switched off to disablecurrent through the induction transmitter that causes a collapse of themagnetic field, and the collapse of the magnetic field causes a transferof the energy from the induction transmitter to the induction receiver,and charges the capacitor and thereby causes a voltage waveform at adrain of the transistor, and wherein the quasi-resonant flybackconverter further comprises a comparator with two input terminalscoupled to either side of the capacitor between the capacitor and thedrain of the transistor, the comparator being configured to detect atrough in the voltage waveform during the off-interval in which thetransistor is switched off, and in response produce an output to causethe transistor to switch on for the on-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the quasi-resonant flyback converter further comprisesfirst and second voltage dividers whose inputs are coupled to eitherside of the capacitor, the two input terminals of the comparator beingcoupled to outputs of respective ones of the first and second voltagedividers and thereby coupled to either side of the capacitor.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isalso configured to implement a pulse-width modulation (PWM) controllerthat is configured to receive the output from the comparator, and inresponse drive the transistor to switch on for the on-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isalso configured to implement a glitch filter that is configured toreceive and remove glitch pulses from the output of the comparator.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by a coprocessor that isembodied as a programmable system-on-chip (PSoC), and that is alsoconfigured to implement a pulse-width modulation (PWM) controller and aglitch filter coupled to and between the comparator and PWM controller,and

wherein the glitch filter is configured to receive and remove glitchpulses from the output of the comparator and thereby produce a filteredoutput, and the PWM controller is configured to receive the filteredoutput, and in response drive the transistor to switch on for theon-interval.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the comparator is implemented by an individualelectronic component or a circuit constructed of discrete electroniccomponents.

These and other features, aspects, and advantages of the presentdisclosure will be apparent from a reading of the following detaileddescription together with the accompanying drawings, which are brieflydescribed below. The present disclosure includes any combination of two,three, four or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedor otherwise recited in a specific example implementation describedherein. This disclosure is intended to be read holistically such thatany separable features or elements of the disclosure, in any of itsaspects and example implementations, should be viewed as combinable,unless the context of the disclosure clearly dictates otherwise.

It will therefore be appreciated that this Brief Summary is providedmerely for purposes of summarizing some example implementations so as toprovide a basic understanding of some aspects of the disclosure.Accordingly, it will be appreciated that the above described exampleimplementations are merely examples and should not be construed tonarrow the scope or spirit of the disclosure in any way. Other exampleimplementations, aspects and advantages will become apparent from thefollowing detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of some described example implementations.

BRIEF DESCRIPTION OF THE DRAWING(S)

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIGS. 1 and 2 illustrate a perspective view of an aerosol deliverydevice comprising a cartridge and a control body that are respectivelycoupled to one another and decoupled from one another, according to anexample implementation of the present disclosure;

FIGS. 3 and 4 illustrate respectively an exploded view of and asectional view through the control body of FIG. 1 in which an inductiontransmitter thereof defines a tubular configuration, according to anexample implementation;

FIG. 5 illustrates a sectional view through the control body of FIG. 1in which an induction transmitter thereof defines a coiledconfiguration, according to an example implementation;

FIGS. 6 and 7 illustrate respectively an exploded view of and asectional view through the cartridge of FIG. 1 in which a substratethereof extends into an internal compartment defined by a container,according to an example implementation;

FIG. 8 illustrates a sectional view through the aerosol delivery deviceof FIG. 1 including the control body of FIG. 3 and the cartridge of FIG.6, according to an example implementation;

FIGS. 9 and 10 illustrate a perspective view of an aerosol deliverydevice comprising a control body and an aerosol source member that arerespectively coupled to one another and decoupled from one another,according to another example implementation of the present disclosure;

FIGS. 11 and 12 illustrate respectively a front view of and a sectionalview through an aerosol delivery device according to an exampleimplementation;

FIGS. 13 and 14 illustrate respectively a front view of and a sectionalview through an aerosol delivery device according to another exampleimplementation;

FIGS. 15 and 16 illustrate respectively a front view of and a sectionalview through a support cylinder according to an example implementation;and

FIGS. 17 and 18 illustrate a quasi-resonant flyback converter accordingto some example implementations.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example implementations thereof. These exampleimplementations are described so that this disclosure will be thoroughand complete, and will fully convey the scope of the disclosure to thoseskilled in the art. Indeed, the disclosure may be embodied in manydifferent forms and should not be construed as limited to theimplementations set forth herein; rather, these implementations areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification and the appended claims, thesingular forms “a,” “an,” “the” and the like include plural referentsunless the context clearly dictates otherwise. Also, while reference maybe made herein to quantitative measures, values, geometric relationshipsor the like, unless otherwise stated, any one or more if not all ofthese may be absolute or approximate to account for acceptablevariations that may occur, such as those due to engineering tolerancesor the like.

As described hereinafter, example implementations of the presentdisclosure relate to aerosol delivery devices. Aerosol delivery devicesaccording to the present disclosure use electrical energy to heat amaterial (preferably without combusting the material to any significantdegree) to form an inhalable substance; and components of such systemshave the form of articles most preferably are sufficiently compact to beconsidered hand-held devices. That is, use of components of preferredaerosol delivery devices does not result in the production of smoke inthe sense that aerosol results principally from by-products ofcombustion or pyrolysis of tobacco, but rather, use of those preferredsystems results in the production of vapors resulting fromvolatilization or vaporization of certain components incorporatedtherein. In some example implementations, components of aerosol deliverydevices may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol generating pieces of certain preferred aerosol delivery devicesmay provide many of the sensations (e.g., inhalation and exhalationrituals, types of tastes or flavors, organoleptic effects, physicalfeel, use rituals, visual cues such as those provided by visibleaerosol, and the like) of smoking a cigarette, cigar or pipe that isemployed by lighting and burning tobacco (and hence inhaling tobaccosmoke), without any substantial degree of combustion of any componentthereof. For example, the user of an aerosol generating piece of thepresent disclosure can hold and use that piece much like a smokeremploys a traditional type of smoking article, draw on one end of thatpiece for inhalation of aerosol produced by that piece, take or drawpuffs at selected intervals of time, and the like.

While the systems are generally described herein in terms ofimplementations associated with aerosol delivery devices such asso-called “e-cigarettes,” it should be understood that the mechanisms,components, features, and methods may be embodied in many differentforms and associated with a variety of articles. For example, thedescription provided herein may be employed in conjunction withimplementations of traditional smoking articles (e.g., cigarettes,cigars, pipes, etc.), heat-not-burn cigarettes, and related packagingfor any of the products disclosed herein. Accordingly, it should beunderstood that the description of the mechanisms, components, features,and methods disclosed herein are discussed in terms of implementationsrelating to aerosol delivery devices by way of example only, and may beembodied and used in various other products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer body or shell, which maybe referred to as a housing. The overall design of the outer body orshell can vary, and the format or configuration of the outer body thatcan define the overall size and shape of the aerosol delivery device canvary. Typically, an elongated body resembling the shape of a cigaretteor cigar can be a formed from a single, unitary housing or the elongatedhousing can be formed of two or more separable bodies. For example, anaerosol delivery device can comprise an elongated shell or body that canbe substantially tubular in shape and, as such, resemble the shape of aconventional cigarette or cigar. In one example, all of the componentsof the aerosol delivery device are contained within one housing.Alternatively, an aerosol delivery device can comprise two or morehousings that are joined and are separable. For example, an aerosoldelivery device can possess at one end a control body comprising ahousing containing one or more reusable components (e.g., an accumulatorsuch as a rechargeable battery and/or rechargeable supercapacitor, andvarious electronics for controlling the operation of that article), andat the other end and removably coupleable thereto, an outer body orshell containing a disposable portion (e.g., a disposableflavor-containing cartridge). More specific formats, configurations andarrangements of components within the single housing type of unit orwithin a multi-piece separable housing type of unit will be evident inlight of the further disclosure provided herein. Additionally, variousaerosol delivery device designs and component arrangements can beappreciated upon consideration of the commercially available electronicaerosol delivery devices.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and ceasing power for heat generation, such asby controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater (e.g., anelectrical resistance or induction heater or component(s) commonlyreferred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., a solid tobacco material, a semi-solid tobaccomaterial or a liquid aerosol precursor composition), and a mouth endregion or tip for allowing draw upon the aerosol delivery device foraerosol inhalation (e.g., a defined airflow path through the articlesuch that aerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific implementations, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heater may bepositioned sufficiently near the aerosol precursor composition so thatheat from the heater can volatilize the aerosol precursor (as well asone or more flavorants, medicaments, or the like that may likewise beprovided for delivery to a user) and form an aerosol for delivery to theuser. When the heater heats the aerosol precursor composition, anaerosol is formed, released, or generated in a physical form suitablefor inhalation by a consumer. It should be noted that the foregoingterms are meant to be interchangeable such that reference to release,releasing, releases, or released includes form or generate, forming orgenerating, forms or generates, and formed or generated. Specifically,an inhalable substance is released in the form of a vapor or aerosol ormixture thereof, wherein such terms are also interchangeably used hereinexcept where otherwise specified.

As noted above, the aerosol delivery device may incorporate a battery orother power source to provide current flow sufficient to provide variousfunctionalities to the aerosol delivery device, such as powering of aheater, powering of control systems, powering of indicators, and thelike. The power source can take on various implementations. Preferably,the power source is able to deliver sufficient power to rapidly activatethe heater to provide for aerosol formation and power the aerosoldelivery device through use for a desired duration of time. The powersource preferably is sized to fit conveniently within the aerosoldelivery device so that the aerosol delivery device can be easilyhandled. Additionally, a preferred power source is of a sufficientlylight weight to not detract from a desirable smoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices.

As described hereinafter, the present disclosure relates to aerosoldelivery devices. Aerosol delivery devices may be configured to heat anaerosol precursor composition to produce an aerosol. The aerosolprecursor composition may comprise one or more of a solid tobaccomaterial, a semi-solid tobacco material, and a liquid aerosol precursorcomposition. In some implementations, the aerosol delivery devices maybe configured to heat and produce an aerosol from a fluid aerosolprecursor composition (e.g., a liquid aerosol precursor composition).Such aerosol delivery devices may include so-called electroniccigarettes.

Representative types of liquid aerosol precursor components andformulations are set forth and characterized in U.S. Pat. No. 7,726,320to Robinson et al., U.S. Pat. No. 9,254,002 to Chong et al.; and U.S.Pat. App. Pub. Nos. 2013/0008457 to Zheng et al.; 2015/0020823 toLipowicz et al.; and 2015/0020830 to Koller, as well as PCT Pat. App.Pub. No. WO 2014/182736 to Bowen et al.; and U.S. Pat. No. 8,881,737 toCollett et al., the disclosures of which are incorporated herein byreference. Other aerosol precursors that may be employed include theaerosol precursors that have been incorporated in any of a number of therepresentative products identified above. Also desirable are theso-called “smoke juices” for electronic cigarettes that have beenavailable from Johnson Creek Enterprises LLC. Implementations ofeffervescent materials can be used with the aerosol precursor, and aredescribed, by way of example, in U.S. Pat. App. Pub. No. 2012/0055494 toHunt et al., which is incorporated herein by reference. Further, the useof effervescent materials is described, for example, in U.S. Pat. No.4,639,368 to Niazi et al.; U.S. Pat. No. 5,178,878 to Wehling et al.;U.S. Pat. No. 5,223,264 to Wehling et al.; U.S. Pat. No. 6,974,590 toPather et al.; U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat.No. 8,424,541 to Crawford et al; U.S. Pat. No. 8,627,828 to Stricklandet al.; and U.S. Pat. No. 9,307,787 to Sun et al., as well as US Pat.App. Pub. Nos. 2010/0018539 to Brinkley et al.; and PCT Pat. App. Pub.No. WO 97/06786 to Johnson et al., all of which are incorporated byreference herein.

In other implementations, the aerosol delivery devices may compriseheat-not-burn devices, configured to heat a solid aerosol precursorcomposition (e.g., an extruded tobacco rod) or a semi-solid aerosolprecursor composition (e.g., a glycerin-loaded tobacco paste).Representative types of solid and semi-solid aerosol precursorcompositions and formulations are disclosed in U.S. Pat. No. 8,424,538to Thomas et al.; U.S. Pat. No. 8,464,726 to Sebastian et al.; U.S. Pat.App. Pub. No. 2015/0083150 to Conner et al.; U.S. Pat. App. Pub. No.2015/0157052 to Ademe et al.; and U.S. Pat. App. Pub. No. 2017/0000188to Nordskog et al., all of which are incorporated by reference herein.

Regardless of the type of aerosol precursor composition heated, aerosoldelivery devices may include a heater configured to heat the aerosolprecursor composition. In some implementations, the heater is aninduction heater. Such heaters often comprise an induction transmitterand an induction receiver. The induction transmitter may include a coilconfigured to create an oscillating magnetic field (e.g., a magneticfield that varies periodically with time) when alternating current isdirected therethrough. The induction receiver may be at least partiallyreceived within the induction transmitter and may include a conductivematerial. By directing alternating current through the inductiontransmitter, eddy currents may be generated in the induction receivervia induction. The eddy currents flowing through the resistance of thematerial defining the induction receiver may heat it by Joule heating(i.e., through the Joule effect). The induction receiver, which maydefine an atomizer, may be wirelessly heated to form an aerosol from anaerosol precursor composition positioned in proximity to the inductionreceiver.

The amount of heat produced by the induction receiver may beproportional to the square of the electrical current times theelectrical resistance of the material of the induction receiver. Inimplementations of the induction receiver comprising ferromagneticmaterials, heat may also be generated by magnetic hysteresis losses.Several factors contribute to the temperature rise of the inductionreceiver including, but not limited to, proximity to the inductiontransmitter, distribution of the magnetic field, electrical resistivityof the material of the induction receiver, saturation flux density, skineffects or depth, hysteresis losses, magnetic susceptibility, magneticpermeability, and dipole moment of the material.

In this regard, both the induction transmitter and induction receivermay comprise an electrically conductive material. By way of example, theinduction transmitter and/or the induction receiver may comprise variousconductive materials including metals such as cooper and aluminum,alloys of conductive materials (e.g., diamagnetic, paramagnetic, orferromagnetic materials) or other materials such as a ceramic or glasswith one or more conductive materials imbedded therein. In anotherimplementation, the induction receiver may comprise conductiveparticles. In some implementations, the induction receiver may be coatedwith or otherwise include a thermally conductive passivation layer(e.g., a thin layer of glass).

In some examples, the induction transmitter and the induction receivermay form an electrical transformer. In some examples, the transformerand associated circuitry including the PWM inverter may be configured tooperate according to a suitable wireless power transfer standard such asthe Qi interface standard developed by the Wireless Power Consortium(WPC), the Power Matters Alliance (PMA) interface standard developed bythe PMA, the Rezence interface standard developed by the Alliance forWireless Power (A4WP), and the like.

In some implementations aerosol delivery devices may include a controlbody and a cartridge in the case of so-called electronic cigarettes, ora control body and an aerosol source member in the case of heat-not-burndevices. In the case of either electronic cigarettes or heat-not-burndevices, the control body may be reusable, whereas the cartridge/aerosolsource member may be configured for a limited number of uses and/orconfigured to be disposable. The cartridge/aerosol source member mayinclude the aerosol precursor composition. In order to heat the aerosolprecursor composition, the heater may be positioned proximate theaerosol precursor composition, such as across the control body andcartridge, or in the control body in which the aerosol source member maybe positioned. The control body may include a power source, which may berechargeable or replaceable, and thereby the control body may be reusedwith multiple cartridges/aerosol source members. The control body mayalso include a flow sensor to detect when a user draws on thecartridge/aerosol source member.

In more specific implementations, one or both of the control body andthe cartridge/aerosol source member may be referred to as beingdisposable or as being reusable. For example, the control body may havea power source such as a replaceable battery or a rechargeable battery,solid-state battery, thin-film solid-state battery, rechargeablesupercapacitor or the like, and thus may be combined with any type ofrecharging technology, including connection to a wall charger,connection to a car charger (i.e., cigarette lighter receptacle), andconnection to a computer, such as through a universal serial bus (USB)cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection toa photovoltaic cell (sometimes referred to as a solar cell) or solarpanel of solar cells, or wireless radio frequency (RF) based charger.Further, in some implementations in the case of an electronic cigarette,the cartridge may comprise a single-use cartridge, as disclosed in U.S.Pat. No. 8,910,639 to Chang et al., which is incorporated herein byreference.

Examples of power sources are described in U.S. Pat. No. 9,484,155 toPeckerar et al., and U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,filed Oct. 21, 2015, the disclosures of which are incorporated herein byreference. With respect to the flow sensor, representative currentregulating components and other current controlling components includingvarious microcontrollers, sensors, and switches for aerosol deliverydevices are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al.,U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 toFleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S.Pat. No. 8,205,622 to Pan, all of which are incorporated herein byreference. Reference also is made to the control schemes described inU.S. Pat. No. 9,423,152 to Ampolini et al., which is incorporated hereinby reference.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puff in an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference in their entireties.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higginset al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 toFelter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No.7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No.7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan; U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231 to Thorens etal.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al.; U.S. Pat. No. 9,220,302 to DePiano etal.; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon; U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub.No. 2010/0307518 to Wang; PCT Pat. App. Pub. No. WO 2010/091593 to Hon;and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference. Further, U.S. Pat. App. Pub. No.2017/0099877 to Worm et al., discloses capsules that may be included inaerosol delivery devices and fob-shape configurations for aerosoldelivery devices, and is incorporated herein by reference. A variety ofthe materials disclosed by the foregoing documents may be incorporatedinto the present devices in various implementations, and all of theforegoing disclosures are incorporated herein by reference in theirentireties.

FIGS. 1-8 illustrate implementations of an aerosol delivery deviceincluding a control body and a cartridge in the case of an electroniccigarette. More specifically, FIG. 1 illustrates an aerosol deliverydevice 100 according to an example implementation of the presentdisclosure. As indicated, the aerosol delivery device may include acontrol body 102 and a cartridge 104. The control body and the cartridgecan be permanently or detachably aligned in a functioning relationship.In this regard, FIG. 1 illustrates the aerosol delivery device in acoupled configuration, whereas FIG. 2 illustrates the aerosol deliverydevice in a decoupled configuration. Various mechanisms may connect thecartridge to the control body to result in a threaded engagement, apress-fit engagement, an interference fit, a magnetic engagement, or thelike. The aerosol delivery device may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome implementations when the control body and the cartridge are in anassembled configuration.

FIG. 3 illustrates an exploded view of the control body 102 of theaerosol delivery device 100 according to an example implementation ofthe present disclosure. As illustrated, the control body may comprise aninduction transmitter 302, an outer body 304, a flow sensor 306 (e.g., apuff sensor or pressure switch), a control component 308 (e.g., amicroprocessor, individually or as part of a microcontroller, a printedcircuit board (PCB) that includes a microprocessor and/ormicrocontroller, etc.), a spacer 310, a power source 312 (e.g., abattery, which may be rechargeable, and/or a rechargeablesupercapacitor), a circuit board with an indicator 314 (e.g., a lightemitting diode (LED)), a connector circuit 316, and an end cap 318.

In one implementation, the indicator 314 may comprise one or more LEDs,quantum dot-based LEDs or the like. The indicator can be incommunication with the control component 308 through the connectorcircuit 316 and be illuminated, for example, during a user drawing on acartridge (e.g., cartridge 104 of FIG. 2) coupled to the control body102, as detected by the flow sensor 306. The end cap 318 may be adaptedto make visible the illumination provided thereunder by the indicator.Accordingly, the indicator may be illuminated during use of the aerosoldelivery device 100 to simulate the lit end of a smoking article.However, in other implementations, the indicator can be provided invarying numbers and can take on different shapes and can even be anopening in the outer body (such as for release of sound when suchindicators are present).

Each of the components of the control body 102 may be at least partiallyreceived in the outer body 304. The outer body may extend from anengagement end 304′ to an outer end 304″. The end cap 318 may bepositioned at, and engaged with, the outer end of the outer body.Thereby, the end cap, which may be translucent or transparent, may beilluminated by the indicator 314 in order to simulate the lit end of asmoking article or perform other functions as described above. Theopposing engagement end of the outer body may be configured to engagethe cartridge 104.

FIG. 4 schematically illustrates a partial sectional view through thecontrol body 102 proximate the engagement end 304′ of the outer body304. As illustrated, the induction transmitter 302 may extend proximatethe engagement end of the outer body. In one implementation, asillustrated in FIGS. 3 and 4, the induction transmitter may define atubular configuration. As illustrated in FIG. 4, the inductiontransmitter may include a coil support 402 and a coil 404. The coilsupport, which may define a tubular configuration, may be configured tosupport the coil such that the coil does not move into contact with, andthereby short-circuit with, the induction receiver or other structures.The coil support may comprise a nonconductive material, which may besubstantially transparent to the oscillating magnetic field produced bythe coil. The coil may be imbedded in, or otherwise coupled to, the coilsupport. In the illustrated implementation, the coil is engaged with aninner surface of the coil support so as to reduce any losses associatedwith transmitting the oscillating magnetic field to the inductionreceiver. However, in other implementations, the coil may be positionedat an outer surface of the coil support or fully imbedded in the coilsupport. Further, in some implementations, the coil may comprise anelectrical trace printed on or otherwise coupled to the coil support, ora wire. In either implementation, the coil may define a helicalconfiguration.

In an alternate implementation, as illustrated in FIG. 5, the inductiontransmitter 302 may include the coil 404 without the coil support 402.In each implementation, the induction transmitter may define an innerchamber 406 about which the induction transmitter extends.

As further illustrated in FIGS. 3-5, in some implementations, theinduction transmitter 302 may be coupled to a support member 320. Thesupport member may be configured to engage the induction transmitter andsupport the induction transmitter within the outer body 304. Forexample, the induction transmitter may be imbedded in, or otherwisecoupled to the support member, such that the induction transmitter isfixedly positioned within the outer body. By way of further example, theinduction transmitter may be injection molded into the support member.

The support member 320 may engage an internal surface of the outer body304 to provide for alignment of the support member with respect to theouter body. Thereby, as a result of the fixed coupling between thesupport member and the induction transmitter 302, a longitudinal axis ofthe induction transmitter may extend substantially parallel to alongitudinal axis of the outer body. Thus, the induction transmitter maybe positioned out of contact with the outer body, so as to avoidtransmitting current from the induction transmitter to the outer body.However, in some implementations, as shown in FIG. 5, an optionalinsulator 502 may be positioned between the induction transmitter 302and the outer body 304, so as to prevent contact therebetween. As may beunderstood, the insulator and the support member may comprise anynonconductive material such as an insulating polymer (e.g., plastic orcellulose), glass, rubber, and porcelain. Alternatively, the inductiontransmitter may contact the outer body in implementations in which theouter body is formed from a nonconductive material such as a plastic,glass, rubber, or porcelain.

As described below in detail, the induction transmitter 302 may beconfigured to receive an electrical current from the power source 312and wirelessly heat the cartridge 104 (see, e.g., FIG. 2). Thus, asillustrated in FIGS. 4 and 5, the induction transmitter may includeelectrical connectors 408 configured to supply the electrical currentthereto. For example, the electrical connectors may connect theinduction transmitter to the control component. Thereby, current fromthe power source may be selectively directed to the inductiontransmitter as controlled by the control component. For example, thecontrol component 312 may direct current from the power source (see,e.g., FIG. 3) to the induction transmitter when a draw on the aerosoldelivery device 100 is detected by the flow sensor 306. The electricalconnectors may comprise, by way of example, terminals, wires, or anyother implementation of connector configured to transmit electricalcurrent therethrough. Further, the electrical connectors may include anegative electrical connector and a positive electrical connector.

In some implementations, the power source 312 may comprise a batteryand/or a rechargeable supercapacitor, which may supply direct current.As described elsewhere herein, operation of the aerosol delivery devicemay require directing alternating current to the induction transmitter302 to produce an oscillating magnetic field in order to induce eddycurrents in the induction receiver. Accordingly, in someimplementations, the control component 308 of the control body 102 mayinclude an inverter or an inverter circuit configured to transformdirect current provided by the power source to alternating current thatis provided to the induction transmitter.

FIG. 6 illustrates an exploded view of the cartridge 600 that in someexamples may correspond to the cartridge 104 of FIG. 1. As illustrated,the cartridge 600 may include an induction receiver 602, an outer body604, a container 606, a sealing member 608, and a substrate 610 that mayinclude an aerosol precursor composition. The outer body 604 may extendbetween an engagement end 604′ and an outer end 604″. Some or all of theremaining components of the cartridge 600 may be positioned at leastpartially within the outer body 604.

The cartridge 600 may additionally include a mouthpiece 612. Themouthpiece 612 may be integral with the outer body 604 or the container606 or a separate component. The mouthpiece 612 may be positioned at theouter end 604″ of the outer body 604.

FIG. 7 illustrates a sectional view through the cartridge 600 in anassembled configuration. As illustrated, the container 606 may bereceived within the outer body 604. Further the sealing member 608 maybe engaged with the container 606 to define an internal compartment 614.As further illustrated in FIG. 7, in some implementations, the sealingmember 608 may additionally engage the outer body 604.

In some implementations, the sealing member 608 may comprise an elasticmaterial such as a rubber or silicone material. In theseimplementations, the sealing material 608 may compress to form a tightseal with the container 606 and/or the outer body 604. An adhesive maybe employed to further improve the seal between the sealing member 608and the container 606 and/or the outer body 604. In anotherimplementation, the sealing member 608 may comprise an inelasticmaterial such as a plastic material or a metal material. In theseimplementations, the sealing member 608 may be adhered or welded (e.g.,via ultrasonic welding) to the container 606 and/or the outer body 604.Accordingly, via one or more of these mechanisms, the sealing member 608may substantially seal the internal compartment 614 shut.

The induction receiver 602 may be engaged with the sealing member 608.In one implementation, the induction receiver 602 may be partiallyimbedded in the sealing member 608. For example, the induction receiver602 may be injection molded into the sealing member 608 such that atight seal and connection is formed therebetween. Accordingly, thesealing member 608 may retain the induction receiver at a desiredposition. For example, the induction receiver 602 may be positioned suchthat a longitudinal axis of the induction receiver extends substantiallycoaxially with a longitudinal axis of the outer body 604.

Further, the substrate 610 may engage the sealing member 608. In oneimplementation, the substrate 610 may extend through the sealing member608. In this regard, the sealing member 608 may define an aperture 616extending therethrough, and through which the substrate 610 is received.Thereby, the substrate 610 may extend into the internal compartment 614.For example, as illustrated in FIG. 7, an end of the substrate 610 maybe received in a pocket 618 defined by the container 606. Accordingly,the container 606 and the sealing member 608 may each engage thesubstrate 610 and cooperatively maintain the substrate at a desiredposition. For example, a longitudinal axis of the substrate 610 may bepositioned substantially coaxial with a longitudinal axis of theinduction receiver 602. Thereby, as illustrated, in someimplementations, the substrate 610 may be positioned in proximity to,but out of contact with, the induction receiver 602. By avoiding directcontact between the substrate 610 and the induction receiver 602, theinduction coil may remain substantially free of residue buildup fromuse, and hence the cartridge may optionally be refilled with aerosolprecursor composition and/or a new substrate or otherwise reused.However, as discussed below, direct contact between the substrate andthe induction receiver may be preferable in some implementations.

In implementations of the cartridge 104 wherein the aerosol precursorcomposition comprises a liquid or other fluid, the substrate 610 may beconfigured to retain the aerosol precursor composition therein andrelease a vapor therefrom when heat is applied thereto by the inductionreceiver 602 in the manner described below. In some implementations, thesubstrate 610 may retain a sufficient quantity of the aerosol precursorcomposition to last a desired extent. In other implementations it may bepreferable to provide the cartridge 104 with an increased capacity ofthe aerosol precursor composition. Examples of materials that may beemployed in the substrate 610 in implementations wherein the substrateis configured to hold a fluid aerosol precursor composition include aporous ceramic, carbon, cellulose acetate, polyethylene terephthalate,fiberglass, and porous sintered glass.

In this regard, as illustrated by way of example in FIGS. 6 and 7, inone implementation, the container 606 may comprise a reservoir and theinternal compartment 614 may be configured to receive the liquid aerosolprecursor composition. In this implementation, the substrate 610 maycomprise a liquid transport element (e.g., a wick) configured to receivethe aerosol precursor composition from the internal compartment 614 andtransport the aerosol precursor composition therealong. Accordingly, theaerosol precursor composition may be transported from the internalcompartment 614 to locations along the longitudinal length of thesubstrate 610 about which the induction receiver 602 extends.

As may be understood, the implementation of the cartridge 600illustrated in FIG. 7 is provided for example purposes only. In thisregard, various alternative implementations of cartridges 104 areprovided herein by way of further example. Note that although theimplementations of the cartridge are described separately herein, eachof the respective components and features thereof may be combined in anymanner except as may be otherwise noted herein. Other implementations ofthe aerosol delivery device, control body and cartridge are described inU.S. Pat. App. Pub. No. 2017/0127722 to Davis et al.; U.S. Pat. App.Pub. No. 2017/0202266 to Sur et al.; and U.S. patent application Ser.No. 15/352,153 to Sur et al., filed Nov. 15, 2016, all of which areincorporated by reference herein. Further, various examples of controlcomponents and functions performed thereby are described in U.S. Pat.App. Pub. No. 2014/0096782 to Sears et al., which is incorporated hereinby reference.

As noted above, each of the cartridges 104 of the present disclosure isconfigured to operate in conjunction with the control body 102 toproduce an aerosol. By way of example, FIG. 8 illustrates the cartridge600 engaged with the control body. As illustrated, when the control bodyis engaged with the cartridge 600, the induction transmitter 302 may atleast partially surround, preferably substantially surround, and morepreferably fully surround the induction receiver 602 (e.g., by extendingaround the circumference thereof). Further, the induction transmitter302 may extend along at least a portion of the longitudinal length ofthe induction receiver 602, and preferably extend along a majority ofthe longitudinal length of the induction receiver, and most preferablyextend along substantially all of the longitudinal length of theinduction receiver.

Accordingly, the induction receiver 602 may be positioned inside of theinner chamber 406 about which the induction transmitter 302 extends.Accordingly, when a user draws on the mouthpiece 612 of the cartridge600, the pressure sensor 306 may detect the draw. Thereby, the controlcomponent 308 may direct current from the power source 312 (see, e.g.,FIG. 3) to the induction transmitter 302. The induction transmitter 302may thereby produce an oscillating magnetic field. As a result of theinduction receiver 602 being received in the inner chamber 406, theinduction receiver may be exposed to the oscillating magnetic fieldproduced by the induction transmitter 302.

According to example implementations, a change in current in theinduction transmitter 302, as directed thereto from the power source 312(see, e.g., FIG. 3) by the control component 308, may produce analternating electromagnetic field that penetrates the induction receiver602, thereby generating electrical eddy currents within the inductionreceiver that heat the induction receiver through the Joule effect, asdescribed above. The alternating electromagnetic field may be producedby directing alternating current to the induction transmitter 302. Asnoted above, in some implementations, the control component 308 mayinclude an inverter or inverter circuit configured to transform directcurrent provided by the power source 312 to alternating current that isprovided to the induction transmitter 302.

Accordingly, the induction receiver 602 may be heated. The heat producedby the induction receiver 602 may heat the substrate 610 including theaerosol precursor composition, such that an aerosol 802 is produced.Accordingly, the induction receiver 602 may comprise an atomizer. Bypositioning the induction receiver 602 around the substrate 610 at asubstantially uniform distance therefrom (e.g., by aligning thelongitudinal axes of the substrate and the induction receiver), thesubstrate and the aerosol precursor composition may be substantiallyuniformly heated.

The aerosol 802 may travel around or through the induction receiver 602and the induction transmitter 302. For example, as illustrated, in oneimplementation, the induction receiver 602 may comprise a mesh, ascreen, a helix, a braid, or other porous structure defining a pluralityof apertures extending therethrough. In other implementations, theinduction receiver may comprise a rod imbedded in a substrate orotherwise in contact with an aerosol precursor composition, a pluralityof beads or particles imbedded in a substrate or otherwise in contactwith an aerosol precursor composition, or a sintered structure. In eachof these implementations, the aerosol 802 may freely pass through theinduction receiver 602 and/or the substrate to allow the aerosol totravel through the mouthpiece to the user.

The aerosol 802 may mix with air 804 entering through inlets 410 (see,e.g., FIG. 4), which may be defined in the control body 102 (e.g., inthe outer body 304). Accordingly, an intermixed air and aerosol 806 maybe directed to the user. For example, the intermixed air and aerosol 806may be directed to the user through one or more through holes 626defined in the outer body 604 of the cartridge 600. In someimplementations, the sealing member 608 may additionally include throughholes 628 extending therethrough, which may align with the through holes626 defined through the outer body 604. However, as may be understood,the flow pattern through the aerosol delivery device 100 may vary fromthe particular configuration described above in any of various mannerswithout departing from the scope of the present disclosure.

FIGS. 9-16 illustrate implementations of an aerosol delivery deviceincluding a control body and an aerosol source member in the case of aheat-not-burn device. More specifically, FIG. 9 illustrates an aerosoldelivery device 900 according to an example implementation of thepresent disclosure. The aerosol delivery device may include a controlbody 902 and an aerosol source member 904. In various implementations,the aerosol source member and the control body can be permanently ordetachably aligned in a functioning relationship. In this regard, FIG. 9illustrates the aerosol delivery device in a coupled configuration,whereas FIG. 10 illustrates the aerosol delivery device in a decoupledconfiguration. Various mechanisms may connect the aerosol source memberto the control body to result in a threaded engagement, a press-fitengagement, an interference fit, a sliding fit, a magnetic engagement,or the like. In various implementations, the control body of the aerosoldelivery device may be substantially rod-like, substantially tubularshaped, or substantially cylindrically shaped (such as, for example, theimplementations of the present disclosure shown in FIGS. 9-14). In otherimplementations, the control body may take another hand-held shape, suchas a small box shape.

In various implementations of the present disclosure, the aerosol sourcemember 904 may comprise a heated end 1002, which is configured to beinserted into the control body 902, and a mouth end 1004, upon which auser draws to create the aerosol. In various implementations, at least aportion of the heated end may include an aerosol precursor composition1006 (sometimes referred to as an inhalable substance medium). The anaerosol precursor composition may comprise tobacco-containing beads,tobacco shreds, tobacco strips, reconstituted tobacco material, orcombinations thereof, and/or a mix of finely ground tobacco, tobaccoextract, spray dried tobacco extract, or other tobacco form mixed withoptional inorganic materials (such as calcium carbonate), optionalflavors, and aerosol forming materials to form a substantially solid ormoldable (e.g., extrudable) substrate. In various embodiments, theaerosol source member, or a portion thereof, may be wrapped in anoverwrap material 1008, which may be formed of any material useful forproviding additional structure and/or support for the aerosol sourcemember. In various implementations, the overwrap material may comprise amaterial that resists transfer of heat, which may include a paper orother fibrous material, such as a cellulose material. The overwrapmaterial may also include at least one filler material imbedded ordispersed within the fibrous material. In various implementations, thefiller material may have the form of water insoluble particles.Additionally, the filler material can incorporate inorganic components.In various implementations, the overwrap may be formed of multiplelayers, such as an underlying, bulk layer and an overlying layer, suchas a typical wrapping paper in a cigarette. Such materials may include,for example, lightweight “rag fibers” such as flax, hemp, sisal, ricestraw, and/or esparto.

In various implementations, the mouth end of the aerosol source member904 may include a filter 1010, which may be made of a cellulose acetateor polypropylene material. In various implementations, the filter mayincrease the structural integrity of the mouth end of the aerosol sourcemember, and/or provide filtering capacity, if desired, and/or provideresistance to draw. For example, an article according to the inventioncan exhibit a pressure drop of about 50 to about 250 mm water pressuredrop at 17.5 cc/second air flow. In further implementations, pressuredrop can be about 60 mm to about 180 mm or about 70 mm to about 150 mm.Pressure drop value may be measured using a Filtrona Filter Test Station(CTS Series) available from Filtrona Instruments and Automation Ltd or aQuality Test Module (QTM) available from the Cerulean Division ofMolins, PLC. The thickness of the filter along the length of the mouthend of the aerosol source member can vary—e.g., about 2 mm to about 20mm, about 5 mm to about 20 mm, or about 10 mm to about 15 mm. In someimplementations, the filter may be separate from the overwrap, and thefilter may be held in position by the overwrap. Example types ofoverwrapping materials, wrapping material components, and treatedwrapping materials that may be used in overwrap in the presentdisclosure are described in U.S. Pat. No. 5,105,838 to White et al.;U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No. 5,220,930 toGentry; U.S. Pat. No. 6,908,874 to Woodhead et al.; U.S. Pat. No.6,929,013 to Ashcraft et al.; U.S. Pat. No. 7,195,019 to Hancock et al.;U.S. Pat. No. 7,276,120 to Holmes; U.S. Pat. No. 7,275,548 to Hancock etal.; PCT WO 01/08514 to Fournier et al.; and PCT WO 03/043450 toHajaligol et al., which are incorporated herein by reference.Representative wrapping materials are commercially available as R. J.Reynolds Tobacco Company Grades 119, 170, 419, 453, 454, 456, 465, 466,490, 525, 535, 557, 652, 664, 672, 676 and 680 from Schweitzer-MauditInternational. The porosity of the wrapping material can vary, andfrequently is between about 5 CORESTA units and about 30,000 CORESTAunits, often is between about 10 CORESTA units and about 90 CORESTAunits, and frequently is between about 8 CORESTA units and about 80CORESTA units.

To maximize aerosol and flavor delivery which otherwise may be dilutedby radial (i.e., outside) air infiltration through the overwrap 1008,one or more layers of non-porous cigarette paper may be used to envelopthe aerosol source member 904 (with or without the overwrap present).Examples of suitable non-porous cigarette papers are commerciallyavailable from Kimberly-Clark Corp. as KC-63-5, P878-5, P878-16-2 and780-63-5. Preferably, the overwrap is a material that is substantiallyimpermeable to the vapor formed during use of the inventive article. Ifdesired, the overwrap can comprise a resilient paperboard material,foil-lined paperboard, metal, polymeric materials, or the like, and thismaterial can be circumscribed by a cigarette paper wrap. The overwrapmay comprise a tipping paper that circumscribes the component andoptionally may be used to attach a filter material to the aerosol sourcemember, as otherwise described herein.

In various implementations other components may exist between the anaerosol precursor composition 1006 and the mouth end 1004 of the aerosolsource member 904, wherein the mouth end may include a filter. Forexample, in some implementations one or any combination of the followingmay be positioned between the an aerosol precursor composition and themouth end: an air gap; phase change materials for cooling air; flavorreleasing media; ion exchange fibers capable of selective chemicaladsorption; aerogel particles as filter medium; and other suitablematerials.

Various implementations of the present disclosure employ an inductionheater to heat the aerosol precursor composition 1006. The inductionheater may comprise a transformer, which may comprise an inductiontransmitter and an induction receiver. In various implementations, oneor both of the induction transmitter and induction receiver may belocated in the control body and/or the aerosol source member. In someinstances, the an aerosol precursor composition may include a pluralityof beads or particles imbedded in, or otherwise part of, the aerosolprecursor composition that may serve as, or facilitate the function of,an induction receiver.

FIG. 11 illustrates a front view of an aerosol delivery device 900according to an example implementation of the present disclosure, andFIG. 12 illustrates a sectional view through the aerosol delivery deviceof FIG. 11. As illustrated in these figures, the aerosol delivery deviceof this example implementation includes a transformer comprising aninduction transmitter and an induction receiver. In particular, thecontrol body 902 of the depicted implementation may comprise a housing1102 that includes an opening 1104 defined in an engaging end thereof, aflow sensor 1106 (e.g., a puff sensor or pressure switch), a controlcomponent 1108 (e.g., a microprocessor, individually or as part of amicrocontroller, a PCB that includes a microprocessor and/ormicrocontroller, etc.), a power source 1110 (e.g., a battery, which maybe rechargeable, and/or a rechargeable supercapacitor), and an end capthat includes an indicator 1112 (e.g., a LED).

In one implementation, the indicator 1112 may comprise one or more LEDs,quantum dot-based LEDs or the like. The indicator can be incommunication with the control component 1108 and be illuminated, forexample, when a user draws on the aerosol source member 904, whencoupled to the control body 902, as detected by the flow sensor 1106.

The control body 902 of the implementation depicted in FIGS. 11 and 12includes an induction transmitter and an induction receiver thattogether form the transformer. The transformer of variousimplementations of the present disclosure may take a variety of forms,including implementations where one or both of the induction transmitterand induction receiver are located in the control body or the aerosoldelivery device 900. In the particular implementation depicted in FIGS.11 and 12, the induction transmitter comprises a laminate that includesa foil material 1114 that surrounds a support member 1116 (a supportcylinder as illustrated), and the induction receiver of the depictedembodiment comprises a plurality of receiver prongs 1118 that extendfrom a receiver base member 1120. In some implementations, the foilmaterial may include an electrical trace printed thereon, such as, forexample, one or more electrical traces that may, in someimplementations, form a helical pattern when the foil material ispositioned around the induction receiver. In various implementations,the induction receiver and the induction transmitter may be constructedof one or more conductive materials, and in further implementations theinduction receiver may be constructed of a ferromagnetic materialincluding, but not limited to, cobalt, iron, nickel, and combinationsthereof. In the illustrated implementation, the foil material isconstructed of a conductive material and the receiver prongs areconstructed of a ferromagnetic material. In various implementations, thereceiver base member may be constructed of a non-conductive and/orinsulating material.

As illustrated, the induction transmitter (foil material 1114) mayextend proximate an engagement end of the housing 1102, and may beconfigured to substantially surround the portion of the heated end 1002of the aerosol source member 904 that includes the aerosol precursorcomposition 1006. In such a manner, the induction transmitter of theillustrated implementation may define a tubular configuration. Asillustrated in FIGS. 11 and 12, the induction transmitter may surroundthe support member 1116. The support cylinder may also define a tubularconfiguration, and may be configured to support the foil material suchthat the foil material does not move into contact with, and therebyshort-circuit with, the induction receiver prongs 1118. In such amanner, the support cylinder may comprise a nonconductive material,which may be substantially transparent to an oscillating magnetic fieldproduced by the foil material. In various implementations, the foilmaterial may be imbedded in, or otherwise coupled to, the supportcylinder. In the illustrated implementation, the foil material isengaged with an outer surface of the support cylinder; however, in otherimplementations, the foil material may be positioned at an inner surfaceof the support cylinder or be fully imbedded in the support cylinder.

In the illustrated implementation, the support cylinder 1116 may alsoserve to facilitate proper positioning of the aerosol source member 904when the aerosol source member is inserted into the housing 1102. Inparticular, the support cylinder may extend from the opening 1104 of thehousing to the receiver base member 1120. In the illustratedimplementation, an inner diameter of the support cylinder may beslightly larger than or approximately equal to an outer diameter of acorresponding aerosol source member (e.g., to create a sliding fit) suchthat the support cylinder guides the aerosol source member into theproper position (e.g., lateral position) with respect to the controlbody 902. In the illustrated implementation, the control body isconfigured such that when the aerosol source member is inserted into thecontrol body, the receiver prongs 1118 are located in the approximateradial center of the heated end 1002 of the aerosol source member. Insuch a manner, when used in conjunction with an extruded aerosolprecursor composition that defines a tube structure, the receiver prongsare located inside of a cavity defined by an inner surface of theextruded tube structure, and thus do not contact the inner surface ofthe extruded tube structure.

In various implementations, the transmitter support member 1116 mayengage an internal surface of the housing 1102 to provide for alignmentof the support member with respect to the housing. Thereby, as a resultof the fixed coupling between the support member and the inductiontransmitter, (foil material 1114) a longitudinal axis of the inductiontransmitter may extend substantially parallel to a longitudinal axis ofthe housing. In various implementations, the induction transmitter maybe positioned out of contact with the housing, so as to avoidtransmitting current from the transmitter coupling device to the outerbody. In some implementations, an insulator may be positioned betweenthe induction transmitter and the housing, so as to prevent contacttherebetween. As may be understood, the insulator and the support membermay comprise any nonconductive material such as an insulating polymer(e.g., plastic or cellulose), glass, rubber, ceramic, and porcelain.Alternatively, the induction transmitter may contact the housing inimplementations in which the housing is formed from a nonconductivematerial such as a plastic, glass, rubber, ceramic, or porcelain.

An alternate implementation is illustrated in FIGS. 13 and 14. Similarto the implementation described with respect to FIGS. 11 and 12, theimplementation depicted in FIGS. 13 and 14 includes an aerosol deliverydevice 1300 comprising a control body 1302 that is configured to receivean aerosol source member 1304. As noted above, the aerosol source membermay comprise a heated end, which is configured to be inserted into thecontrol body, and a mouth end 1306, upon which a user draws to createthe aerosol. At least a portion of the heated end may include an aerosolprecursor composition 1308, which may comprise tobacco-containing beads,tobacco shreds, tobacco strips, reconstituted tobacco material, orcombinations thereof, and/or a mix of finely ground tobacco, tobaccoextract, spray dried tobacco extract, or other tobacco form mixed withoptional inorganic materials (such as calcium carbonate), optionalflavors, and aerosol forming materials to form a substantially solid ormoldable (e.g., extrudable) substrate. In various implementations, theaerosol source member, or a portion thereof, may be wrapped in anoverwrap material 1310, which may be formed of any material useful forproviding additional structure and/or support for the aerosol sourcemember. In various implementations, the overwrap material may comprise amaterial that resists transfer of heat, which may include a paper orother fibrous material, such as a cellulose material. Variousconfigurations of possible overwrap materials are described with respectto the example implementation of FIGS. 3 and 4 above.

In various implementations, the mouth end 1306 of the aerosol sourcemember 1304 may include a filter 1312, which may be made of a celluloseacetate or polypropylene material. As noted above, in variousimplementations, the filter may increase the structural integrity of themouth end of the aerosol source member, and/or provide filteringcapacity, if desired, and/or provide resistance to draw. In someembodiments, the filter may be separate from the overwrap, and thefilter may be held in position near the cartridge by the overwrap.Various configurations of possible filter characteristics are describedwith respect to the example implementation of FIGS. 3 and 4 above.

The control body 1302 may comprise a housing 1314 that includes anopening 1316 defined therein, a flow sensor 1318 (e.g., a puff sensor orpressure switch), a control component 1320 (e.g., a microprocessor,individually or as part of a microcontroller, a PCB that includes amicroprocessor and/or microcontroller, etc.), a power source 1322 (e.g.,a battery, which may be rechargeable, and/or a rechargeablesupercapacitor), and an end cap that includes an indicator 1324 (e.g., aLED). As noted above, in one implementation, the indicator may compriseone or more LEDs, quantum dot-based LEDs or the like. The indicator canbe in communication with the control component and be illuminated, forexample, when a user draws on the aerosol source member 1304, whencoupled to the control body, as detected by the flow sensor. Examples ofpower sources, sensors, and various other possible electrical componentsare described above with respect to the example implementation of FIGS.11 and 12 above.

The control body 1302 of the implementation depicted in FIGS. 13 and 14includes an induction transmitter and an induction receiver thattogether form the transformer. The transformer of variousimplementations of the present disclosure may take a variety of forms,including implementations where one or both of the induction transmitterand induction receiver are located in the control body and/or theaerosol delivery device. In the particular implementation depicted inFIGS. 13 and 14, the induction transmitter of the depictedimplementation comprises a helical coil 1326 that surrounds a supportmember 1328 (a support cylinder as illustrated). In variousimplementations, the induction receiver and the induction transmittermay be constructed of one or more conductive materials, and in furtherimplementations the induction receiver may be constructed of aferromagnetic material including, but not limited to, cobalt, iron,nickel, and combinations thereof. In the illustrated implementation, thehelical coil is constructed of a conductive material. In furtherimplementations, the helical coil may include a non-conductiveinsulating cover/wrap material.

The induction receiver of the illustrated implementation comprises asingle receiver prong 1330 that extends from a receiver base member1332. In various implementations a receiver prong, whether a singlereceiver prong, or part of a plurality of receiver prongs, may have avariety of different geometric configurations. For example, in someimplementations the receiver prong may have a cylindrical cross-section,which, in some implementations may comprise a solid structure, and inother implementations, may comprise a hollow structure. In otherimplementations, the receiver prong may have a square or rectangularcross-section, which, in some implementations, may comprise a solidstructure, and in other implementations, may comprise a hollowstructure. In various implementations, the receiver prong may beconstructed of a conductive material. In the illustrated implementation,the receiver prong is constructed of a ferromagnetic material including,but not limited to, cobalt, iron, nickel, and combinations thereof. Invarious implementations, the receiver base member may be constructed ofa non-conductive and/or insulating material.

As illustrated, the induction transmitter (helical coil 1326) may extendproximate an engagement end of the housing 1314, and may be configuredto substantially surround the portion of the heated end of the aerosolsource member 1304 that includes the aerosol precursor composition 1310.As illustrated in FIGS. 13 and 14, the induction transmitter maysurround the support member 1328. The support cylinder, which may definea tubular configuration, may be configured to support the helical coilsuch that the coil does not move into contact with, and therebyshort-circuit with, the induction receiver prong 1330. In such a manner,the support cylinder may comprise a nonconductive material, which may besubstantially transparent to an oscillating magnetic field produced bythe helical coil. In various implementations, the helical coil may beimbedded in, or otherwise coupled to, the support cylinder. In theillustrated implementation, the helical coil is engaged with an outersurface of the support cylinder; however, in other implementations, thehelical coil may be positioned at an inner surface of the supportcylinder or be fully imbedded in the support cylinder.

In the illustrated implementation, the support cylinder 1328 may alsoserve to facilitate proper positioning of the aerosol source member 1304when the aerosol source member is inserted into the housing 1314. Inparticular, the support cylinder may extend from the opening 1319 of thehousing to the receiver base member 1332. In the illustratedimplementation, an inner diameter of the transmitter source cylinder maybe slightly larger than or approximately equal to an outer diameter of acorresponding aerosol source member (e.g., to create a sliding fit) suchthat the support cylinder guides the aerosol source member into theproper position (e.g., lateral position) with respect to the controlbody 1302. In the illustrated implementation, the control body isconfigured such that when the aerosol source member is inserted into thecontrol body, the receiver prong 1330 is located in the approximateradial center of the heated end of the aerosol source member. In such amanner, when used in conjunction with an extruded aerosol precursorcomposition that defines a tube structure, the receiver prong is locatedinside of a cavity defined by an inner surface of the extruded tubestructure, and thus does not contact the inner surface of the extrudedtube structure.

It should be noted that in some implementations, the induction receivermay be a part of an aerosol source member, such as for example, as apart of the aerosol precursor composition of an aerosol source member.Such implementations may or may not include an additional inductionreceiver that is part of the control body. For example, the aerosolprecursor composition may comprises a braided wire structure embeddedinto an extruded tube. The braided wire structure may comprise a seriesof interwoven cross wires that may be constructed of any one or moreconductive materials, and further may be constructed of one or moreferromagnetic materials including, but not limited to, cobalt, iron,nickel, and combinations thereof. In various implementations the braidedwire structure may be proximate an inner surface or outer surface of theaerosol precursor composition, or may be located within the extrudedtube structure.

In various implementations, the transmitter support cylinder may engagean internal surface of the housing to provide for alignment of thesupport cylinder with respect to the housing. Thereby, as a result ofthe fixed coupling between the support cylinder and the inductiontransmitter, a longitudinal axis of the induction transmitter may extendsubstantially parallel to a longitudinal axis of the housing. In variousimplementations, the induction transmitter may be positioned out ofcontact with the housing, so as to avoid transmitting current from thetransmitter coupling device to the outer body. In some implementations,an insulator may be positioned between the induction transmitter and thehousing, so as to prevent contact therebetween. As may be understood,the insulator and the support cylinder may comprise any nonconductivematerial such as an insulating polymer (e.g., plastic or cellulose),glass, rubber, ceramic, and porcelain. Alternatively, the inductiontransmitter may contact the housing in implementations in which thehousing is formed from a nonconductive material such as a plastic,glass, rubber, ceramic, or porcelain.

Although in some implementations, the support cylinder and the receiverbase member may comprise separate components, in other implementations,the support cylinder and the receiver base member may be integralcomponents. For example, FIG. 15 illustrates a front view of a supportmember 1500 according to an example implementation of the presentdisclosure. FIG. 16 illustrates a sectional view through the supportcylinder 1500 of FIG. 15. As depicted in the figures, the supportcylinder comprises a tube configuration configured to support ainduction transmitter, such as, for example, a helical coil. In such amanner, an outer surface of the support cylinder may include one or morecoil grooves 1502 that may be configured to guide, contain, or otherwisesupport an induction transmitter such as a transmitter coil. As depictedin FIG. 16, the support cylinder may integrate with a receiver basemember 1504, which may be attached at one end of the support cylinder.Further, in various implementations an induction receiver, such as inthe case of the illustrated implementation, a single receiver prong 1506may be contained by and extend from the receiver base member. In variousimplementations, the support cylinder and induction receiver (in theillustrated implementation, the receiver prong) may be constructed ofdifferent materials so as to avoid creating a short-circuit with theinduction transmitter. In particular, the support cylinder may comprisea nonconductive material such as an insulating polymer (e.g., plastic orcellulose), glass, rubber, ceramic, porcelain, and combinations thereof,while the induction receiver (in the illustrated implementation, thereceiver prong) may comprise a conductive material. In variousimplementations, the induction receiver (in the depicted implementationthe receiver prong) may be constructed of a ferromagnetic materialincluding, but not limited to, cobalt, iron, nickel, and combinationsthereof.

In the illustrated implementation, the support cylinder is configuredsuch that an induction transmitter, such as a helical coil, may engagewith an outer surface of the support cylinder; however, in otherimplementations, the support cylinder may be configured such that aninduction transmitter may be positioned at an inner surface of thetransmitter support cylinder or fully imbedded in the support cylinder.

Other implementations of the aerosol delivery device, control body andaerosol source member are described in U.S. patent application Ser. No.15/799,365 to Sebastian et al., filed Oct. 31, 2017, which isincorporated herein by reference.

In some examples of either an electronic cigarette or heat-not-burndevice, the transformer including the induction transmitter andinduction receiver may be part of a quasi-resonant flyback converter. Inthis regard, FIG. 17 illustrates a quasi-resonant flyback converter 1700according to some example implementations. As shown, the quasi-resonantflyback converter includes a transformer 1702 including an inductiontransmitter (shown as inductor L1) and an induction receiver (shown asinductor L2). The induction transmitter may correspond to the inductiontransmitter of any of the above example implementations, includinginduction transmitter 302, foil 1114 or helical coil 1326. Similarly,the induction receiver may correspond to the induction receiver of anyof the above example implementations, including induction receiver 602,receiver prongs 1118 or receiver prong 1330.

As also shown, the quasi-resonant flyback converter 1700 includes acapacitor C (or parallel capacitors) that with the induction transmitterL1 forms a tank circuit. The quasi-resonant flyback converter alsoincludes a transistor Q1, such as a metal-oxide-semiconductorfield-effect transistor (MOSFET). The transistor is switchable in cyclesto cause the induction transmitter to generate an oscillating magneticfield and induce an alternating voltage in the induction receiver L2when exposed to the oscillating magnetic field. This alternating voltagecauses the induction receiver to generate heat and thereby vaporizecomponents of the aerosol precursor composition of the aerosol deliverydevice (e.g., device 100, 900, 1300).

According to example implementations, each of the cycles includes anon-interval and an off-interval. In the on-interval, the transistor Q1is switched on to enable current through the induction transmitter L1that causes the induction transmitter to generate a magnetic field inwhich the induction transmitter stores energy. In the off-interval, thetransistor is switched off to disable current through the inductiontransmitter that causes a collapse of the magnetic field. This thecollapse of the magnetic field causes a transfer of the energy from theinduction transmitter to the induction receiver L2, and charges thecapacitor C and thereby causes a voltage waveform at a drain D of thetransistor (the transistor also including a source S and a gate G).

The quasi-resonant flyback converter 1700 also includes a comparator U1with two input terminals +, − coupled to either side of the capacitor Cbetween the capacitor and the drain D of the transistor. In someexamples, as also shown, the quasi-resonant flyback converter 1700further includes first and second voltage dividers 1704 a, 1704 b whoseinputs are coupled to either side of the capacitor C. In these examples,the two input terminals +, − of the comparator U1 are coupled to outputsof respective ones of the first and second voltage dividers and therebycoupled to either side of the capacitor. The comparator is configured todetect a trough in the voltage waveform during the off-interval in whichthe transistor is switched off. And in response, the comparator isconfigured to produce an output to cause the transistor to switch on forthe on-interval.

In some examples, the comparator U1 is implemented by a coprocessor 1706such as a programmable system-on-chip (PSoC), suitable examples of whichinclude the CY8C4Axx family of PSOC® analog coprocessors from CypressSemiconductor. In other examples, the comparator U1 is implemented by anindividual electronic component or a circuit constructed of discreteelectronic components. This is shown in FIG. 18 for a quasi-resonantflyback converter 1800 that is otherwise similar to the quasi-resonantflyback converter 1700 in FIG. 17.

Returning to FIG. 17, in examples including a coprocessor 1706, thecoprocessor may also be configured to implement a pulse-width modulation(PWM) controller 1708 and/or a glitch filter 1710. The PWM controller isconfigured to receive the output from the comparator U1, and in responsedrive the transistor Q1 to switch on for the on-interval. The glitchfilter, which may be coupled to and between the comparator and PWMcontroller, is configured to receive and remove glitch pulses from theoutput of the comparator and thereby produce a filtered output. Inexamples also including both the PWM controller and glitch filter, thePWM controller may configured to receive the filtered output, and inresponse drive the transistor to switch on for the on-interval.

In some examples, the transistor Q1 has a drain-to-source on-stateresistance (R_(DS(on))) that is inversely proportional to a switchingtime of the transistor. In these examples, the on-state resistance isalso directly proportional to a time in which the alternating voltage isinduced in the induction receiver L2 and thereby the heat is generated.

In some examples, the aerosol delivery device 100, 900, 1300 furtherincludes a power source V such as power source 312, 1110, 1322. In theseexamples, the power source is connected to an electrical load thatincludes the transformer 1702, and configured to supply a current to theload. The amount of the heat the induction receiver L2 is caused togenerate is directly proportional to an intensity of the currentsupplied by the power source. In some further examples, the power sourceincludes a rechargeable primary battery and a rechargeable secondarybattery in a parallel combination.

In some examples, the induction receiver L2 includes a coil. In theseexamples, an amount of the heat the induction receiver is caused togenerate is directly proportional to a length of the coil.

Many modifications and other implementations of the disclosure will cometo mind to one skilled in the art to which this disclosure pertainshaving the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the disclosure is not to be limited to the specificimplementations disclosed herein and that modifications and otherimplementations are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. An aerosol delivery device comprising an aerosolprecursor composition and a quasi-resonant flyback converter configuredto cause components of the aerosol precursor composition to vaporize toproduce an aerosol, the quasi-resonant flyback converter comprising: atransformer including an induction transmitter and an inductionreceiver; a capacitor that with the induction transmitter forms a tankcircuit; and a transistor that is switchable in cycles to cause theinduction transmitter to generate an oscillating magnetic field andinduce an alternating voltage in the induction receiver when exposed tothe oscillating magnetic field, the alternating voltage causing theinduction receiver to generate heat and thereby vaporize components ofthe aerosol precursor composition, wherein each of the cycles includesan on-interval and an off-interval, and the quasi-resonant flybackconverter further comprises a comparator with two input terminalscoupled to either side of the capacitor between the capacitor and adrain of the transistor, the comparator being configured to detect atrough in a voltage waveform at the drain of the transistor during theoff-interval in which the transistor is switched off, and in responseproduce an output to cause the transistor to switch on for theon-interval.
 2. The aerosol delivery device of claim 1, wherein theaerosol precursor composition includes a solid tobacco material, asemi-solid tobacco material or a liquid aerosol precursor composition.3. The aerosol delivery device of claim 1, wherein the quasi-resonantflyback converter further comprises first and second voltage dividerswhose inputs are coupled to either side of the capacitor, the two inputterminals of the comparator being coupled to outputs of respective onesof the first and second voltage dividers and thereby coupled to eitherside of the capacitor.
 4. The aerosol delivery device of claim 1,wherein the comparator is implemented by a coprocessor that is alsoconfigured to implement a pulse-width modulation (PWM) controller thatis configured to receive the output from the comparator, and in responsedrive the transistor to switch on for the on-interval.
 5. The aerosoldelivery device of claim 4, wherein the coprocessor is furtherconfigured to implement a glitch filter coupled to and between thecomparator and PWM controller, the glitch filter being configured toreceive and remove glitch pulses from the output of the comparator andthereby produce a filtered output, and the PWM controller is configuredto receive the filtered output, and in response drive the transistor toswitch on for the on-interval.
 6. The aerosol delivery device of claim4, wherein the coprocessor is embodied as a programmable system-on-chip(PSoC).
 7. The aerosol delivery device of claim 1, wherein thecomparator is implemented by a coprocessor that is also configured toimplement a glitch filter that is configured to receive and removeglitch pulses from the output of the comparator.
 8. The aerosol deliverydevice of claim 7, wherein the coprocessor is embodied as a programmablesystem-on-chip (PSoC).
 9. The aerosol delivery device of claim 1,wherein the comparator is implemented by a coprocessor that is embodiedas a programmable system-on-chip (PSoC), and that is also configured toimplement a pulse-width modulation (PWM) controller and a glitch filtercoupled to and between the comparator and PWM controller, and whereinthe glitch filter is configured to receive and remove glitch pulses fromthe output of the comparator and thereby produce a filtered output, andthe PWM controller is configured to receive the filtered output, and inresponse drive the transistor to switch on for the on-interval.
 10. Theaerosol delivery device of claim 1, wherein the comparator isimplemented by an individual electronic component or a circuitconstructed of discrete electronic components.
 11. The aerosol deliverydevice of claim 1, wherein the transistor has a drain-to-source on-stateresistance (R_(DS(on))) that is inversely proportional to a switchingtime of the transistor, and that is directly proportional to a time inwhich the alternating voltage is induced in the induction receiver andthereby the heat is generated.
 12. The aerosol delivery device of claim1 further comprising a power source connected to an electrical load thatincludes the transformer, the power source being configured to supply acurrent to the load, an amount of the heat the induction receiver iscaused to generate being directly proportional to an intensity of thecurrent supplied by the power source.
 13. The aerosol delivery device ofclaim 12, wherein the power source includes a rechargeable primarybattery and a rechargeable secondary battery in a parallel combination.14. The aerosol delivery device of claim 1, wherein the inductionreceiver includes a coil, an amount of the heat the induction receiveris caused to generate being directly proportional to a length of thecoil.
 15. A control body for an aerosol delivery device, the controlbody comprising: a housing having an opening defined in one end thereof,the opening configured to receive an aerosol source member that definesa heated end and a mouth end and includes an aerosol precursorcomposition; and within the housing, a quasi-resonant flyback convertercomprising: a transformer including an induction transmitter and aninduction receiver; a capacitor that with the induction transmitterforms a tank circuit; and a transistor that is switchable in cycles tocause the induction transmitter to generate an oscillating magneticfield and induce an alternating voltage in the induction receiver whenexposed to the oscillating magnetic field, the alternating voltagecausing the induction receiver to generate heat and, when the aerosolsource member is inserted into the housing, vaporize components of theaerosol precursor composition to produce an aerosol, wherein each of thecycles includes an on-interval and an off-interval, and thequasi-resonant flyback converter further comprises a comparator with twoinput terminals coupled to either side of the capacitor between thecapacitor and a drain of the transistor, the comparator being configuredto detect a trough in a voltage waveform at the drain of the transistorduring the off-interval in which the transistor is switched off, and inresponse produce an output to cause the transistor to switch on for theon-interval.
 16. The control body of claim 15, wherein thequasi-resonant flyback converter further comprises first and secondvoltage dividers whose inputs are coupled to either side of thecapacitor, the two input terminals of the comparator being coupled tooutputs of respective ones of the first and second voltage dividers andthereby coupled to either side of the capacitor.
 17. The control body ofclaim 15, wherein the comparator is implemented by a coprocessor that isalso configured to implement a pulse-width modulation (PWM) controllerthat is configured to receive the output from the comparator, and inresponse drive the transistor to switch on for the on-interval.
 18. Thecontrol body of claim 15, wherein the comparator is implemented by acoprocessor that is also configured to implement a glitch filter that isconfigured to receive and remove glitch pulses from the output of thecomparator.
 19. The control body of claim 15, wherein the comparator isimplemented by a coprocessor that is embodied as a programmablesystem-on-chip (PSoC), and that is also configured to implement apulse-width modulation (PWM) controller and a glitch filter coupled toand between the comparator and PWM controller, and wherein the glitchfilter is configured to receive and remove glitch pulses from the outputof the comparator and thereby produce a filtered output, and the PWMcontroller is configured to receive the filtered output, and in responsedrive the transistor to switch on for the on-interval.
 20. The controlbody of claim 15, wherein the comparator is implemented by an individualelectronic component or a circuit constructed of discrete electroniccomponents.
 21. A control body for an aerosol delivery device, thecontrol body comprising: a housing coupled or coupleable with acartridge that is equipped with an induction receiver and contains anaerosol precursor composition; and within the housing, a quasi-resonantflyback converter comprising: an induction transmitter that with theinduction receiver forms a transformer; a capacitor that with theinduction transmitter forms a tank circuit; and a transistor that isswitchable in cycles to cause the induction transmitter to generate anoscillating magnetic field and induce an alternating voltage in theinduction receiver when the housing is coupled with the cartridge andthe induction receiver is exposed to the oscillating magnetic field, thealternating voltage causing the induction receiver to generate heat andthereby vaporize components of the aerosol precursor composition toproduce an aerosol, wherein each of the cycles includes an on-intervaland an off-interval, and the quasi-resonant flyback converter furthercomprises a comparator with two input terminals coupled to either sideof the capacitor between the capacitor and a drain of the transistor,the comparator being configured to detect a trough in a voltage waveformat the drain of the transistor during the off-interval in which thetransistor is switched off, and in response produce an output to causethe transistor to switch on for the on-interval.
 22. The control body ofclaim 21, wherein the quasi-resonant flyback converter further comprisesfirst and second voltage dividers whose inputs are coupled to eitherside of the capacitor, the two input terminals of the comparator beingcoupled to outputs of respective ones of the first and second voltagedividers and thereby coupled to either side of the capacitor.
 23. Thecontrol body of claim 21, wherein the comparator is implemented by acoprocessor that is also configured to implement a pulse-widthmodulation (PWM) controller that is configured to receive the outputfrom the comparator, and in response drive the transistor to switch onfor the on-interval.
 24. The control body of claim 21, wherein thecomparator is implemented by a coprocessor that is also configured toimplement a glitch filter that is configured to receive and removeglitch pulses from the output of the comparator.
 25. The control body ofclaim 21, wherein the comparator is implemented by a coprocessor that isembodied as a programmable system-on-chip (PSoC), and that is alsoconfigured to implement a pulse-width modulation (PWM) controller and aglitch filter coupled to and between the comparator and PWM controller,and wherein the glitch filter is configured to receive and remove glitchpulses from the output of the comparator and thereby produce a filteredoutput, and the PWM controller is configured to receive the filteredoutput, and in response drive the transistor to switch on for theon-interval.
 26. The control body of claim 21, wherein the comparator isimplemented by an individual electronic component or a circuitconstructed of discrete electronic components.